Welding electrode



Nov. 10, 1936. v. MILLER ET AL 2,060,682

WELDING ELECTRODE Filed Oct. 19, 1935 Inventor-s \lirdis Miller,

Joseph H. Humbers fione,

6 8W 2 a. I E g2 Attorney Patented Nov. 10, 1936 5 UNITED ST T S PATENT OFFICE WELDING ELECTRODE Virdls Miller and Joseph H. Humberstone, Schenectady, N. Y

., assignors to General Electric Company, a corporation of New York Application October 19, 1935, Serial No. 45,743

I 35 Claims. (01. 219-4) The quality of the weld metal deposited by such a process depends to a large extentupon the influence of certain elements or compounds associated with the electrode, usually in theiorm of a coating. Electrodes so coated are commonly referred to as flux coated electrodes.

The flux coating, besides having a definite effeet on the arcing characteristics of the electrode, also protects the deposited weld metal from the influence oi the surrounding atmosphere. The coating may also serve as a carrier for certain alloying elements whichduring the welding operation are incorporated in the weld forming a deposit of desired characteristics.

It is an object 0! our invention'to provide an improved flux coated electrode suitable for building up rail ends and for many other semi-hard It is a further object ofour invention to provide an electrode which during welding produces avery wide, flat, and smooth bead of weld metal.

Further objects of our invention will appear from the following description taken'in' connection with the accompanying drawing which illustrates one embodiment thereof. I

The flux coating of the present. invention is characterized primarily by the use of silicon carbide and term-manganese in conjunction with constituents suitable ifor forming a glassy slag. that will not react with the weld metal. The ratio of the silicon carbide to the ferro-man ganese may be varied, but, when the coating is applied to a mild steel rod, a deposit of desiredhardness for rail welding is obtainedwhen these two materials are used in substantially the same percentage by weight. The combined weightot the silicon carbide and term-manganese in the flux may vary from 15 to 50 per cent, these two ingredients being presentin the flux in substantially equal parts by weight. An electrode having a manganese content of from .40% to .60% and a carbon'content of from .13% to .18% in the presence of a coating containing silicon carbide and form-manganese in substantially equal percentages, each of which forms about 15% of the total weight of the flux employed, will deposit weld metal having a manganese content of 1.25% and a carbon content of 25%.

The presence of silicon carbide in the flux causes the arc to'operate at a voltage between 40 and 50 volts which is much higher than the normal operating voltage of heavy coated electrodes. In the arcv the silicon carbide apparently disassociates into its constituent elements silicon and carbon. Sufiiclent silicon carbide is used so that enough silicon is present to serve as a deoxidlzer and also permit a certain amount of silicon to be added to the weld metal. The presence of the silicon in the weld metal increases its fluidity. That part of the silicon that acts as a deoxidlzer permits the carbon provided by the silicon carbide and the manganese of the term-manganese to enter in the weld deposit in substantial quantities without combining with the oxygen of the surrounding atmosphere in which the welding operation is being performed. The increased operating voltage of the electrode and the alloying action occurring in the weld deposit is believed to be responsibe for the wide, flat and smooth bead produced which is admirably suited for surfacing operation.

The constituents of the flux other than the Terra-manganese and silicon carbide may vary considerably without departing from the spirit and scope of our invention; Apparently all that is necessary is that these additional constituents form during welding a glassy slag which will cover the .weld deposit without reacting with it and protect it from the surrounding atmosphere. The flux when applied as a. heavy coating also forms at the arcing terminal of the electrode a projecting sleeve which surrounds the end of the electrode and protects it from the action of the atmosphere. vaporize during welding and produce a shield of gets about the arc and the metal deposited from the electrode into the weld. This shielding effect may be greatly increased by providing the The constituents of the flux also electrode with a cellulosic covering which is impregnated with theflux. The reducing atmosphere produced by the burning of the cellulosic matu'ial apparently assists in the dissociation of the silicon carbide and increases its effectivene-duringwelding.

Theelectrode illustratedinthedrawing comprisesacoreofmildsteellhavingaheavynux coatinglofsubstantiallythefollowing compoms flux is applied to the core of the electrode in coniunction with a coating of fibrous cellulodc material which is impregnated therewith. This materialmaybeacottontapewhichisfoided longimdinallyaboutthecoreoftheelectrode withitsedgesabuttingoneanotherandparaliel totbeaxisthereof.asdescribedandclaimedin United States Letters Patent 2.010.890. granted ctober0,l085ontbeappiicationofoneofus. Serial No. 640,051. Joseph H. Humberstone. filed December 23. 1032 for Welding electrodes. and assigned to the same assignee as the present application. The tape is usually applied to the coreoftheelectrodesoastoobtsinambstantial layerofnuxbetweenitandtheooreofthe electrode.

In the process of manufacturing such an electrode, it has been found desirable to hold the tape about the core of the electrode by means of ahelicalblndlngl. Thisbindingismadeofa flat strip, the turns of which are placed a substantial distance from one another, as illustrated in the drawing. This binding, when colored, may indicate the flux composition employed on the electrode.

A core of substantially the following composition':

Carbon .13 to .18 per cent Manganese .40 to .60 per cent Phosphorus .04 per cent maximum Sulphur .04 per cent maximum Silicon .025 per cent maximum 0 Iron. Remainder when provided with a coating of the particular composition above described will produce a weld -deposit having a manganese content of 1.35% and a carbon content of The tensile strength of this deposit is from 100,000 to 105,000 pounds per square inch as deposited. It has an impact value of about 20 foot pounds. The hardness of the deposit will average about 805 Brinell when deposited on a rail of 268 Brinell. m This is a most desirable ratio for if the deposit were of 500 to 560 Brinell. there would be a tendency for it to crack and spall under the cold working caused by the wheels of the rolling stock moving over the rails. On the other hand, if it as were softer than the rail, it would batter down quickly and be of little use.

As has been noted above, the weld metal is deposited as a very wide, flat. and smooth bead requiring but a small amount of grinding to adapt it as a finished surface for reconditioned rail ends. In the majority of cases. one layer of deposit metal is sufflcient to build up the average battered rail end, the deposited metal being so smooth as to present no difficulty from tramc (I passing over the deposit before grinding. The

technique of applying the deposit may vary widely. One recommended method is that ilius trated. described, and claimed in Letters Patent No. 1,976,526, Bernard C. Tracey, October 0. i0, assignedtothesameassigneeasthepresentlnl vention. Best results are obtained by holding alongarcandoverlappingeachpreviousbsad by one-half. Because the weld metal depodts canwithanelectrodeofthisinvenflonbemsds asthinasdesiredthetimeandexpenserequh'ed ll forgrindingthedeposittoproduceaflnillsd surface is reduced to a minimum.

The electrode is suitable for surfacing many wearing parts because it produces hard. w's' resisting, and work hardening deposits. The are ll shielding action of its heavy flux coating main tainsastabieflexiblearcandpermitsahfll welding rate together with close regulation 8 the height of the deposit.

Whenusinganeiectrodeoftheabovedescrlbsd I character. the operation is best performed with reverse polarity; that is with the electrode connected to the-positive terminal of the sourced supply, although straight polarity has been used successfully. Theelectrodemayaisobeuldl succpesfully with alternating current sources at sup The electrode illustrated in the drawing h a short length rod such as would usually be employed in hand welding operation. The uppm' 3| endoftheelectrodehasbeenbaredoffluxin order to adapt it for use in an electrode holder hp means of which welding mount is supplied Ch.- to. Electrodes may be made in accordance with our invention in long lengths for use in semi-auto- I matic machines by means of which the electrode is fed toward and away from the work to strike and thereafter maintain a welding are by mean of a mechanism which functions in response to a characteristic of the welding are such as its curl rent or voltage. In such automatic machines the welding current may be supplied to the electrode through incisions made in the flux coating a other openings provided by removing a pol-tin of the coating from the electrode. 0

Aside from the ferro-manganese and silica: carbide constituents of the flux, the nu: composition may vary widely. We prefer to use. however, as ilux constituents suitable for forming a glassy slag, oxides of iron and titanium in com- II bination with silicates of aluminum, magnesium. and the alkaline metals. An aluminum flake clay of approximately the following composition:

Percent Aluminum oxide 38 to I Silica 45 to t! Ignition loss 13 to 14 has been successfully substituted for the feldspar and talc of the above specifically described m composition. A flux of the following composition may be used:

Per cent Fem-manganese 10 Silicon carbide ll Ilmenite II Aluminum flake clay '1 Liquid sodium silicate 28 Water d In making fluxes in accordance with our invention, the solid materials may be reduced to a fine powder which is mixed with a liquid sodium sillcate. This material preferably has a spec gravity of 40 Baum. an NasO content of about i 8%, and a ratio 01' NazO to SiO: approximately 1 to 3.25. A silicate of this composition loses about 01' its moisture on drying. Water is added to the flux in order to control its consistency and adapt it for use as a. smooth paste which is applied to the electrode. By the addition of more water a thinner paste may be produced which is useful in applying thin coatings. The compositions above specifically described are adapted for use as heavy coatings which are of sufficient thickness to produce during welding 9. depending sleeve about the arcing terminal of the electrode and a slag deposit of sufllcient volume to cover the weld metal.

It is of course apparent that a flux in accordance with our invention will produce beneficial results whether it is applied to the electrode as a coating or associated therewith in any other suitable manner. For example, the flux may be enclosed within a channel within the electrode or placed in grooves or depressions in the surface of the electrode without departing from our invention.

What we claim as new and desire to secure by Letters Patent of the United States is:

1. A welding electrode having a flux coating containing in addition to slag forming ingredients, term-manganese and silicon carbide in substantially equal parts by weight and forming together from to 50 per cent by weight of the flux coating.

2. A welding electrode having a core of mild steel and a flux coating containing constituents forming a glassy slag during welding, ferro-manganese, and silicon carbide, the term-manganese and silicon carbide being present in substantially equal parts by weight and forming together from 15 to 50 per cent by weight of the flux coating.

3. A welding electrode having a core of mild steel and a coating resulting from impregnating a cellulosic material with a flux of which 85 to 50 per cent by weight consists of constituents forming a glassy slag during welding, and 15 to 50 per cent by weight consists of term-manganese and silicon carbide which are present in the flux in substantially equal parts by weight.

4. A coating for arc welding electrodes having substantially the following initial composition:

Per cent by weight Ferro-manganese 14 Silicon carbide 15 Ilmenite 34 Feldspar 5 Talc 4 Liquid sodium silicate Water 3 5. An electrode having a core of substantially the following composition:

Carbon .13 to .18 per cent Manganese .40 to .60 per cent Phosphorus .04 per cent maximum Sulphur .04 per cent maximum Silicon .025 per cent maximum Iron Remainder and a coating resulting from impregnating a cellulosic material with a flux of substantially the following composition:

Per cent JOSEPH H. HUIVIBERSTONE. 

